Alternative I-Stud

Abstract

An i-stud having a web and flanges comprising oriented strand board (OSB) and a method of assembling a wall utilizing the same, wherein the flanges are unitary and non-laminated. The method of assembling a wall may utilize a wall system comprising upper and lower frame members or may utilize existing structural members.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

None

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to materials and methods for wall construction. Specifically, the invention relates to studs fabricated in the shape of an “I” utilizing exclusively oriented strand board, and to methods for assembling a wall using the same.

2. Description of the Prior Art

Construction materials of varying types are well known in the art. For many years, lumber and steel have been used for studs. Studs are commonly understood to be the relatively slender, upright members forming the frame of a wall or partition and covered with drywall, sheetrock, plasterwork, siding, or other finishing material. Traditionally, solid, rectangular studs were made using dimensional lumber products.

Construction materials comprising engineered wood products and structural composite lumber such as oriented strand board (OSB) are gaining in acceptance and popularity. U.S. Pat. No. 6,772,572 to Henthorn is directed to a fabricated OSB stud. It is likewise known to assemble a stud in the form of an “I” using multiple pieces. NASCOR® (Nascor, Inc., Calgary, Alberta, CANADA) manufactures I-joists (also referred to as I-studs) having two dimensional lumber flanges separated by an OSB web, the same being used in the NASCOR® III and IV Wall System. Wood I Beam® joists (Georgia-Pacific Corp., Atlanta, Ga.) utilize FiberStrong® (Georgia-Pacific Corp., Atlanta, Ga.) OSB webs fitted into solid lumber, sawn lumber or laminated veneer lumber (LVL) flanges. None of these products, however, utilizes OSB for both the web and the flanges.

U.S. Pat. No. 6,012,262 to Irving describes an assembled I-beam having an OSB web situated between, and in grooves defined by, a pair of laminated, two-piece OSB flanges. Each flange comprises an inner flange and a reinforcing outer flange, these sub-parts being laminated together. It is fairly well recognized that OSB does not have the tensile strength to resist the bending moment on a joist. Although this assembly may provide added strength for a joist, such a construction requires both additional materials and additional labor to achieve this construction and does not meet the need for an improved stud.

A need exists for an improved I-stud made exclusively of OSB, including unitary and non-laminated OSB flanges, that is yet another suitable alternative to dimensional solid lumber studs and offers all of the benefits of steel while remaining cost effective.

SUMMARY OF THE INVENTION

The present disclosure relates to a novel construction material and method for construction. More specifically, the disclosure is concerned with an I-stud manufactured using exclusively oriented strand board (OSB), and a method of assembling a wall using the same.

It is a first object of the present invention to provide a material for construction that is stronger than light gauge steel cold formed studs, yet lighter than lumber studs, and more cost efficient than either, and a method of using the same.

It is a further object of the present invention to provide a material for construction that uses less wood than traditional lumber studs and is reliably straight while resisting warping, twisting and bowing, and a method of using the same.

It is yet a further object of the present invention to provide a material for construction that does not interfere with wireless communication, is resistant to heat and cold transfer, and can be treated to inhibit microbial growth, and a method of using the same.

It is a further object still of the present invention to provide a material for construction that does not require blocking in order to support cabinets, fixtures or trim, and a method of using the same.

Yet another object of the invention is to provide a material for construction that can be manufactured from up to 100% reclaimed product and from lower quality natural products, and a method of using the same.

It is yet another object of the present invention to provide a material for construction that can be fire resistance treated to meet prevalent building codes, and a method of using the same.

Another object of the invention is to provide a wall system incorporating the construction materials disclosed herein.

Other objects, features, and advantages of the present invention will be readily appreciated from the following description. The description makes reference to the accompanying drawings, which are provided for illustration of the preferred embodiment. However, such embodiment does not represent the full scope of the invention. The subject matter which the inventor does regard as his invention is particularly pointed out and distinctly claimed in the claims at the conclusion of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of the apparatus of the present disclosure.

FIG. 2 is an exploded view of the apparatus depicted in FIG. 1.

FIG. 3 is a perspective view of an alternative embodiment of the apparatus of the present disclosure.

FIG. 4 is a perspective view of an embodiment of the system of the present disclosure.

FIG. 5 is a perspective view of an alternative embodiment of the system of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED AND OTHER EMBODIMENTS

While the making and using of various embodiments of the present disclosure are discussed in detail below, it should be appreciated that the present disclosure provides for inventive concepts capable of being embodied in a variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific manners in which to make and use the disclosed apparatus and are not to be interpreted as limiting the scope of the instant disclosure.

In FIGS. 1 and 2, a stud 10 is depicted. Stud 10 comprises a web 12 and flanges 14, 16, such that when viewed from one end or in cross-section, stud 10 resembles an “I”. Thus, stud 10 may interchangeably be referred to herein as an i-stud. Each of web 12 and flanges 14, 16 are manufactured using oriented strand board (OSB). Flanges 14, 16 are of unitary, one-piece construction and are not laminated. Each flange 14, 16 has a longitudinal channel or groove 18, 20 that is roughly centrally located about a face of the flange and runs the length thereof. Grooves 18, 20 are preferably formed or machined to receive and frictionally engage opposite ends of web 12. Grooves 18, 20 and opposite ends of web 12 are preferably complementarily trapezoidal in shape. In a preferred embodiment, the depth of each groove 18, 20 is approximately one-half the thickness of flange 14, 16.

A bonding agent 22 is provided between web 12 and each groove 18, 20 to assemble stud 10. Bonding agent 22 may be any suitable agent, but is preferably a phenolic resin or urea-formaldehyde. Bonding agent 22 may but need not be the same as the bonding agent utilized in the manufacture of the underlying OSB components of stud 10. As is known the art, bonding agents 22 include drying adhesives as well as heat-activated adhesives.

Stud 10 may be provided with one or more apertures 24 through which wiring, piping or other conduits may be passed or strung. Apertures 24 may be any shape, including but not limited to round, ovoid, square and rectangular. Apertures 24 may also be any size subject to the limitation of the width of web 12 and, as is well known in the art, so as not to compromise the structural integrity of web 12 and stud 10. Apertures 24 are preferably rectangular and measure approximately 2¼ inches by 4 inches in size, so as to accommodate a variety of conventional conduits up to 2 inches in diameter. When multiple apertures 24 are provided, they may be provided at any interval but every 16 inches or so, on center (e.g., from the center of a first aperture 24 to the center of the adjacent aperture 24) along the length of web 12, is preferred.

An alternative embodiment is illustrated in FIG. 3, which depicts a stud 10 having a plurality of spaced apart web members 26 disposed between—and along the length of—flanges 14, 16 in the same manner described above. Like web 12, web members 26 comprise oriented strand board and are preferably of substantially the same thickness as flanges 14, 16. The ends of web members 26 and grooves 18, 20 are also preferably complementarily trapezoidal in shape. It will be appreciated that in this embodiment, the need for apertures 24 is effectively eliminated, but one or more apertures 24 could be provided in individual web members 26. Web members 26 may be distributed lengthwise about stud 10 in any configuration, and may be any length relative to flanges 14, 16, so long as the cumulative length of web members 26 in a given stud 10 is less than the length of flanges 14, 16. Preferably, web members 26 in a given stud 10 are each the same length, and are equidistantly spaced.

Turning to FIG. 4, stud 10 is depicted as part of a wall system 28. In addition to a plurality of vertically oriented, spaced-apart studs 10, wall system 28 features horizontal upper frame member 30, horizontal lower frame member 32, substantially in parallel, and a plurality of brackets 34 for joining studs 10 to the respective frame members. Brackets 34 are joined to flanges 14, 16 of studs 10 and frame members 30, 32 using conventional fasteners 36 such as nails, rivets or screws. Either in combination with or in lieu of fasteners, each bracket 34 has a plurality of clips 38 adapted to fit around, frictionally engage, and secure flanges 14, 16 of stud 10. The number and orientation of fasteners 36 may vary. Alternatively, it is conceivable that wall system 28 may be nail-less.

With respect to FIG. 5, an alternative wall system 40 is shown. In addition to a plurality of vertically-oriented, spaced-apart studs 10, wall system 40 features horizontal upper frame member 42 and horizontal lower frame member 44. Both upper and lower frame members 42, 44 are c-shaped channels adapted to receive and frictionally retain and secure opposite ends of stud 10. An additional conventional fastener 46 such as a nail, rivet or screw may be used to secure stud 10 to frame members 42, 44.

Stud 10 may also be incorporated into conventional wall assemblies or attached directly to existing structural members such as floors, ceilings or joists. In this fashion, stud 10 may be used as a replacement material during repairs or renovation when an entire wall is not being built or rebuilt. ‘Frame member’ as utilized herein shall include specific and/or manufactured components of a wall system as described above, as well as existing, preferably horizontal and elongate, structural members that will serve as the upper or lower end of a wall to be built or replaced.

It will be appreciated by those skilled in the art that the use of studs 10 in wall systems such as those disclosed herein will achieve substantial cost savings over dimensional lumber or steel, without compromising stability.

Thus, the present disclosure has been described in an illustrative manner. It is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Furthermore, whereas the present disclosure has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this disclosure.

Claims

1. An i-stud comprising:

two unitary and non-laminated flanges each having a longitudinal groove roughly centrally located about one side;

a web extending between said flanges, wherein opposite ends of said web are seated and frictionally engaged in said grooves;

wherein said web and said flanges each comprise oriented strand board; and

a bonding agent disposed between said opposite ends of said web and said grooves.

2. The i-stud of claim 1 wherein said web and said flanges are of substantially the same thickness.

3. The i-stud of claim 1 wherein said bonding agent is selected from the group consisting of phenolic resin and urea formaldehyde.

4. The i-stud of claim 1 wherein said web comprises an aperture.

5. The i-stud of claim 4 wherein said web comprises a plurality of apertures spaced apart approximately every 16 inches, on center, along the length of said web.

6. The i-stud of claim 4 wherein said aperture is approximately 2¼ inches wide and approximately 4 inches long.

7. The i-stud of claim 1 wherein said grooves and said opposite ends of said web are complementary and roughly trapezoidal in shape.

8. An i-stud comprising:

two unitary and non-laminated flanges each having a longitudinal groove roughly centrally located about one side;

a plurality of spaced-apart web members extending between said flanges, wherein opposite ends of each said web member are seated and frictionally engaged in said grooves;

wherein said web members and said flanges each comprise oriented strand board and are of substantially the same thickness; and

a bonding agent disposed between said opposite ends of said web members and said grooves.

9. The i-stud of claim 8 wherein the sum of the lengths of said web members is less than the length of said flanges.

10. A method of assembling a wall, comprising the steps of:

providing at least one frame member, and at least one stud, wherein said stud comprises two unitary and non-laminated flanges each having a longitudinal groove roughly centrally located about one side; a web extending between said flanges, wherein opposite ends of said web are seated and frictionally engaged in said grooves; wherein said web and said flanges comprise oriented strand board and are of substantially the same thickness; and a bonding agent disposed between said opposite ends of said web and said grooves; and

securing said at least one stud to at least one of said frame members.

11. The method of claim 10 wherein said at least one stud is secured to at least one of said frame members using a fastener.

12. The method of claim 10 further comprising the steps of:

providing a bracket having a plurality of clips;

securing said clips about said flanges of one of said studs; and

securing said bracket to one of said frame members.

13. The method of claim 12 further comprising the step of securing said bracket to at least one of said flanges of said stud using a fastener.

14. The method of claim 10 wherein said step of providing at least one frame member comprises providing an upper frame member and a lower frame member.

15. The method of claim 14 wherein said upper frame member and said lower frame member are elongate, horizontal and substantially in parallel.